Methods and devices for coupling solar panel support structures and/or securing solar panel support structures to a roof

ABSTRACT

A mounting unit for mounting a solar panel on a roof includes a base having a first flange and a second flange that extend laterally from the base and a mounting surface positioned above the base via walls that connect the mounting surface and the base. The mounting surface is couplable with the solar panel to elevate and orient the solar panel above a surface of the roof. The mounting unit also includes a flexible membrane material that is coupled with the first flange of the base and that extends laterally therefrom. The mounting unit further includes an adhesive or tape that is applied to an underside of the second flange so that the second flange is free of the flexible membrane material. The flexible membrane material is couplable with the roof and the adhesive or tape is adherable to the roof to secure the mounting unit to the roof.

BACKGROUND OF THE INVENTION

Solar or photovoltaic panels or modules are often positioned on the roofof a structure or building to generate electricity in order to operatevarious equipment, machinery, lighting or other fixtures, and the like.The solar panels are often held in place atop the roof by mounting thesolar panel to a frame and attaching the frame to the roof. Commonmethods of attaching the frame to the roof include using pole mountsthat are directly attached to the roof deck via one or more mechanicalfasteners (e.g., bolts, screws, and the like) that penetrate through aportion or the entirety of the roof's structure. The penetrationsthrough the roof present a potential failure point where future waterleakage or other problems may occur. Additional time and cost is alsorequired to seal such penetrations to minimize or eliminate such leakageor other problems. Pole mounts also limit the ability of the solar panelto be easily moved or removed from a roof.

Alternatively, another common method that may not require roofpenetrations includes using ballasted footing mounts, such as concreteblocks, steel bases, paver stones, rocks, and the like. Such ballastedfooting mounts use heavy weight to secure the solar panel and frame tothe roof. The heavy ballasted footing mounts produce concentrated orpoint loads on the roof structure at the point where the ballastedfooting mounts contact the roof's surface. Because roofs are oftendesigned to only support a specified load, which normally includes snowand/or other load types, it is critical not to exceed the structurallimitations of the roof. Heavy concentrated or point loads may placeundue and/or unsafe stress on the roof at the point of contact and/ormay damage components of the roof system even when the heavy point loadsdo not otherwise present a structural risk. Further, the concentrated orpoint load may also crush or compress insulation thereby reducing Rvalue and/or stressing the roof membrane.

The use and/or desire for solar panels on roofs appear to be increasingas individuals and companies find ways to be more environmentallyconscious. As such, there is a constant need for improved methods andsystems for securing solar panels to roofs in such a manner as to notdegrade the performance or useful service life of the roof.

BRIEF SUMMARY OF THE INVENTION

Embodiments of the invention provide methods, devices, and systemsrelated to mounting units for mounting solar panels to a roof of abuilding or structure. In one aspect, embodiments of the inventionprovide a mounting unit for mounting a solar panel on a roof. Themounting unit includes a base that is configured for positioningadjacent the roof. The base includes a first flange and a second flangethat extend laterally from the base. The mounting unit also includes amounting surface that is positioned above the base via walls thatconnect the mounting surface and the base. The mounting surface iscouplable with the solar panel to elevate the solar panel above asurface of the roof and to orient the solar panel at an angle relativeto the roof. The mounting unit further includes a flexible membranematerial that is coupled with the first flange of the base and thatextends laterally therefrom. An adhesive or tape is applied to anunderside of the second flange so that the second flange is free of theflexible membrane material. The flexible membrane material is couplablewith the roof and the adhesive or tape is adherable to the roof tosecure the mounting unit to the roof.

According to another aspect, embodiments of the invention provide amethod of attaching a solar panel mounting unit to a roof. The methodincludes providing a solar panel mounting unit having: a base thatincludes a first flange and a second flange that extend laterally fromthe base; a mounting surface positioned above the base via walls thatconnect the mounting surface and the base; a flexible membrane coupledwith the first flange of the base and extending laterally therefrom; andan adhesive or tape applied to an underside of the second flange so thatthe second flange is free of the flexible membrane material. The methodalso includes coupling the flexible membrane material with the roof tosecure the solar panel mounting unit to the roof and adhesively bondingthe adhesive or tape with the roof to additionally secure the mountingunit to the roof.

In some embodiments, the method further includes aligning a plurality ofmounting units atop a roof by: coupling a flexible membrane material ofa first mounting unit with the roof; positioning a front flange of asecond mounting unit atop the flexible membrane of the first mountingunit; and adhesively bonding, via the adhesive or tape, the front flangeof the second mounting unit with the flexible membrane of the firstmounting unit.

In some embodiments, the method may further include laterally spacing aplurality of mounting units atop the roof by providing a spacing jigthat includes: a first longitudinal section; a first flange member thatextends from a proximal end of the first longitudinal section; a secondlongitudinal section telescopingly disposed within the firstlongitudinal section; and a second flange member that extends from adistal end of the second longitudinal section. In such embodiments, themethod may include positioning a first mounting unit atop the roof,positioning a second mounting unit atop the roof, positioning the firstflange member of the spacing jig within a slot of the mounting surfaceof the first mounting unit, and positioning the second flange member ofthe spacing jig within a slot of the mounting surface of the secondmounting unit. Said positioning of said first and second flange memberswithin said respective slots spaces said first and second mountingunits.

In some embodiments, the method may further include longitudinallyspacing a plurality of mounting units atop the roof by providing aspacing jig that includes: a first longitudinal section; a first flangemember that is pivotally attached to a proximal end of the firstlongitudinal section; a second longitudinal section coupled with thefirst longitudinal section so as to have an angled orientation relativethereto; and a second flange member that extends from a distal end ofthe second longitudinal section. In such embodiments, the method mayinclude positioning a first mounting unit atop the roof; positioning asecond mounting unit atop the roof; positioning the first flange memberof the spacing jig within a slot of the mounting surface of the firstmounting unit; and positioning the second flange member of the spacingjig within a slot of the mounting surface of the second mounting unit.Said positioning of said first and second flange members within saidrespective slots spaces said first and second mounting units.

According to another aspect, embodiments of the invention provide amounting unit for mounting a solar panel on a roof. The mounting unitincludes: a base; a plurality of wall that extend upward from the base;and a mounting surface connected with and positioned above the base viathe plurality of walls. The mounting surface includes a plurality ofslots that are each configured to receive a coupling component thatfacilitates in coupling the solar panel atop the mounting surface. Atleast one slot, and in some embodiments each slot, is reinforced tosecure the solar panel atop the mounting unit and thereby increase thewind uplift resistance of the mounting unit.

According to another aspect, embodiments of the invention provide amethod of reinforcing a solar panel mounting unit. The method includesproviding a solar panel mounting unit having: a base; a plurality ofwall that extend upward from the base; a mounting surface connected withand positioned above the base via the plurality of walls; and aplurality of slots that are formed in the mounting surface andconfigured to receive a coupling component that facilitates in couplingthe solar panel atop the mounting surface. The method also includesreinforcing the plurality of slots so that at least one slot, and insome embodiments each slot, exhibits an increased ability to secure thesolar panel atop the mounting unit, said reinforcement increasing thewind uplift resistance of the mounting unit.

According to another aspect, embodiments of the invention provide anelectrically conductive clamp for a solar panel mounting unit. Theelectrically conductive clamp includes a clamp body having an elongatemid-section, a first end, and a second end opposite the first end, withthe clamp body being made of an electrically conductive material. Thefirst end is configured to couple with a metallic mounting rail of themounting unit so that the first end contacts exposed metal of themounting rail to establish electrical bonding between the clamp body andthe mounting rail. The second end is configured to couple with a solarpanel positioned atop the mounting unit so that the second endelectrically contacts the solar panel and thereby establishes electricalbonding between the mounting rail and the solar panel.

According to another aspect, embodiments of the invention provide amethod of electrically coupling a solar panel with one or morecomponents of a solar panel mounting unit. The method includes providinga solar panel and providing a mounting unit. The mounting unit includesa metallic mounting rail that is configured for coupling with the solarpanel. The method also includes positioning the solar panel atop themounting unit and providing a clamp having an elongate mid-section, afirst end, and a second end opposite the first end, where the clamp ismade of an electrically conductive material. The method further includescoupling the first end of the clamp with the metallic mounting rail ofthe mounting unit so that the first end contacts exposed metal of themounting rail to establish electrical bonding between the clamp and themounting rail, and coupling the second end of the clamp with the solarpanel positioned atop the mounting unit so that the second endelectrically contacts the solar panel and thereby establishes electricalbonding between the mounting rail and the solar panel.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention are described in conjunction withthe appended figures:

FIG. 1 illustrates a perspective view of a mounting unit according to anembodiment of the invention.

FIG. 1A illustrates an embodiment of an insert that may be used with themounting unit of FIG. 1.

FIG. 2 illustrates a perspective view of an elongated mounting unitaccording to an embodiment of the invention.

FIGS. 3A-3C illustrate a side view, front view, and top view of themounting unit of FIG. 1 according to an embodiment of the invention.

FIG. 4 illustrates a perspective exploded view of a mounting unit andflexible membrane according to an embodiment of the invention.

FIG. 5 illustrates a perspective view of the mounting unit of FIG. 4attached to a roof's surface according to an embodiment of theinvention.

FIGS. 6A and 6B illustrate side views of a solar panel being mountedatop a mounting unit according to an embodiment of the invention.

FIG. 6C illustrates a perspective view of the mounting unit of FIGS. 6Aand 6B having the solar panel mounted atop a mounting surface of themounting unit and the mounting unit attached to a roof's surfaceaccording to an embodiment of the invention.

FIG. 7A-7C illustrate various views of a conduit that may be used toconnect channels of adjacent mounting units according to an embodimentof the invention.

FIG. 8 illustrates a method of mounting a solar panel to a roof'ssurface according to an embodiment of the invention.

FIGS. 9A-C illustrate a mounting unit for a solar panel wherein themounting unit includes a flexible material membrane skirt that isattached to at least one flange and less than all the flanges of themounting unit according to an embodiment of the invention.

FIGS. 10A-11C illustrate mounting units having reinforced coupling slotsor mounting features according to an embodiment of the invention.

FIGS. 12A and 12B illustrate a conductive clamp that may be used toelectrically couple conductive pieces of a mounting unit with a solarpanel according to an embodiment of the invention.

FIGS. 13A-C illustrate a coupling member that may be used to span alateral gap between adjacent mounting units and/or reduce wind upliftforces according to an embodiment of the invention.

FIGS. 14A-D illustrate spacing members that may be used to spacemounting units atop a roof according to an embodiment of the invention.

FIGS. 15A and 15 B illustrate a method of mounting adjacent mountingunits atop a roof according to an embodiment of the invention.

In the appended figures, similar components and/or features may have thesame numerical reference label. Further, various components of the sametype may be distinguished by following the reference label by a letterthat distinguishes among the similar components and/or features. If onlythe first numerical reference label is used in the specification, thedescription is applicable to any one of the similar components and/orfeatures having the same first numerical reference label irrespective ofthe letter suffix.

DETAILED DESCRIPTION OF THE INVENTION

The ensuing description provides exemplary embodiments only, and is notintended to limit the scope, applicability or configuration of thedisclosure. Rather, the ensuing description of the embodiments willprovide those skilled in the art with an enabling description forimplementing one or more embodiments. It being understood that variouschanges may be made in the function and arrangement of elements withoutdeparting from the spirit and scope of the invention as set forth in theappended claims. Specific details are given in the following descriptionto provide a thorough understanding of the embodiments. However, it willbe understood by one of ordinary skill in the art that the embodimentsmay be practiced without these specific details. Also, it is noted thatmethods or processes may be depicted as a flowchart or a block diagram.Although a flowchart may describe the operations as a sequentialprocess, many of the operations can be performed in parallel orconcurrently. In addition, the order of the operations may bere-arranged. Further a process could have additional steps not discussedor included in a figure. Furthermore, not all operations in anyparticularly described process may occur in all embodiments.

As used herein, the term solar panel (also referred to herein asphotovoltaic panels or modules) includes any panel or array of solar orphotovoltaic cells. Such panels are used to generate and supplyelectricity, typically in residential and commercial applications. Forexample, solar panels are often installed on the roofs of homes andbuildings to generate and supply electricity to the home or building tooperate various machinery, equipment, components, lighting and/or otherfixtures, and the like. Many buildings and/or homes often includeseveral solar panels arranged in a grid or array that form aphotovoltaic system. The solar panels may be electrically coupled toincrease the power generated and provided to the home or building.

The application references several angles measured relative or withrespect to the base. It should be understood that “relative or withrespect to” the base refers to a surface upon which the base rests,which may be the surface of a roof or other structure. In manyembodiments this surface is substantially equivalent to or roughlyparallel with the surface of the mounting unit's flange. Thus, it shouldbe realized that any specified angle may also, or may alternatively, bemeasured relative or with respect to a surface of the mounting unit'sflange.

Embodiments of the invention provide methods and systems for mounting asolar panel or photovoltaic module to a roof a structure, such as a homeor building. A mounting unit or device may be used to mount the solarpanel to the roof. The mounting unit may be a single hollow componentcomprising various ribs, radiuses, draft angles, thin walls, and/orintegrated mounting hardware to provide a rigid yet lightweightstructure. In other embodiments, the mounting unit may include multiplecomponents or pieces that couple or butt together. The mounting unit mayinclude a base that may define a lower periphery of the mounting unit.The base may include a flange that extends laterally from the mountingunit and extends partially or fully around the lower periphery of themounting unit. The flange may extend out from the mounting unit tobetween about 0.5 inches and about 6 inches, and more commonly betweenabout 2 and about 4 inches. The base's flange may facilitate indistributing the weight of the mounting unit and solar panel, preferablyevenly or uniformly, across a relatively large surface area of the roof,thereby minimizing or eliminating concentrated or point loads. The baseand flange may be positioned adjacent the roof's surface. The mountingunit may be made from a reinforced or un-reinforced plastic, such aspolyethylene, polypropylene, styrene, polyvinyl chloride, and the likeand may be made in one or more pieces or components via vacuum forming,injection molding, and the like. The total weight of the mounting unitmay be between about 10 and about 17 pounds, and more commonly about 12pounds. In some embodiments, the mounting unit distributes a load (e.g.,the weight of the mounting unit, attached solar panel, and any othercomponents) on the roof of less than about 1.0 lb/in² and more commonlyless than about 0.5 lb/in². In a specific embodiment, the applied loadof the mounting unit and solar panel directly on the roof below themounting unit's flange is about 0.3 lb/in² or less.

The mounting unit may also include a mounting surface that is connectedwith the base via a plurality of walls. The mounting surface may beelevated above the base and oriented at an angle relative to the base soas to elevate an attached solar panel above the roof's surface anddirect the solar panel toward sunlight incident on the roof's surface.The mounting surface and/or walls may include ribs that provide rigidityto the mounting unit structure. The ribs may define channels that allowair to access the underside of the solar panel to cool the solar paneland enhance electricity generation or production. The air flowingthrough the channels underneath the solar panel may also equalize windpressure and thereby minimize wind loads placed on the solar paneland/or mounting unit. The walls of the mounting unit may be angled withrespect to the base unit to minimize uplift and/or lateral wind loadsand/or allow individual mounting units to be stacked atop one another tooptimize storage and/or transport.

The mounting surface may also include one or more main channels that aresized larger than the channels defined by the ribs and that areconfigured to receive and/or route one or more electrical wires and/orpower cables that couple with the solar panel. The mounting unit mayinclude one or more longitudinally extending main channels and one ormore transversely extending main channels. The main channels may alsoallow wind pressure equalization and natural convection cooling to occuras described herein. A structure's roof may include additional mountingunits and solar panels arranged in a grid or array and the main channelsmay allow adjacent solar panels to be electrically coupled. Electricallycoupling adjacent solar panels may include routing electrical wires orcables through a telescoping conduit that releasably couples withadjacent mounting units. The mounting surface may also include a groundchannel that allows an electrical ground to be connected with the solarpanel.

The mounting surface may also include one or more mounting features thatallow the mounting unit to releasably couple with the solar panel. Themounting features may include mounting channels that are shaped toreceive an insert that couples with a fastener or fasteners to securethe solar panel to the mounting surface of the mounting unit. The insertand/or mounting channels can comprise an inverted T shape, or othershape, that allows the insert and/or channel to slidingly receive thefasteners, such as a bolt and the like, and that prevents or restrictsremoval of the fasteners in a direction roughly normal or orthogonal tothe mounting surface. The fasteners (e.g., bolt and the like) may extendroughly normal or orthogonal from the mounting surface and may beinserted through an aperture of a mounting component (e.g., a mountingplate having a Z profile) of the solar panel and secured with respectthereto. In some embodiments, the insert may be integrated into themounting surface, such as by molding the insert into the mountingsurface. The integrated insert may provide a more secure attachmentbetween the solar panel and the mounting unit.

The mounting unit may further include a flexible membrane that coupleswith the base, such as the flange. The flexible membrane (also referredto herein as a skirt or flexible skirt) may be made of common roofingmembrane materials such as: Thermo Plastic Olefin (TPO), EthylenePropylene Diene Monomer (EPDM), Polyvinyl Chloride (PVC), thermoplasticvulcanizates (TPV), and/or the other roofing membrane materialsdescribed herein. In one embodiment, the flexible membrane includes aTPO material with a polyester fleece attached to the bottom surface. Thepolyester fleece may enable the mounting unit to be adhesively bonded toan asphaltic or bituminous roof membrane by absorbing liquid adhesivesthat bond the skirt to the textured roof surface. The fleece may bethermally embedded in the bottom of the TPO membrane and provide a goodbonding surface for adhesives to adhere the mounting unit to abituminous, asphaltic, or other roof surface. The flexible membrane maybe bonded to an underside of the flange and may extend laterally beyondthe flange. In some embodiments, the flexible membrane extends beyondthe flange by between about 1 inch and about 5 inches, and more commonlyby about 2 inches. The flexible membrane may be coupled with a membranematerial of the roof, which may include: Thermo Plastic Olefin (TPO),Ethylene Propylene Diene Monomer (EPDM), Polyvinyl Chloride (PVC),thermoplastic vulcanizates (TPV), and the like. The flexible membranemay be coupled with the flange and/or roof membrane via an adhesive,tape, heat welding, mechanical fasteners, and the like. The flexiblemembrane may be a large single piece or strip of material or severalindividual strips or segments of material. If a large single membrane isused for the membrane, an inner portion of the membrane may be removedto allow individual mounting units to be stacked atop one another fortransport and/or storage.

The flexible membrane may allow the mounting unit to easily couple withvarious types of roof surfaces. The membrane material used may beselected based on the roofing material the membrane will couple with.The membrane may also function as a protective layer between the flangeor base and the roof surface, such as by preventing or limiting relativemotion between the flange and the roof surface that otherwise couldresult in roof penetrations and possible leakage. The membrane or skirtmay be made of a flexible or compliant material to compensate for smallvariations in the roof's surface, thereby functioning to ensure a firmand continuous bond between the mounting unit and the roof's surface.For example, the flexible membrane may conform to and bond with unevenand/or rough surfaces of the roof and thereby form a continuous bondwith roof's surface. The membrane may further function to allow themounting unit and solar panel to be easily removed from the roof'ssurface. For example, the membrane may be removed (e.g., cut) from theroof or mounting unit so that the mounting unit and attached solar panelmay be uncoupled from the roof. The mounting unit may then be fittedwith another membrane and the mounting unit and/or solar panelreattached to the roof or attached to a different roof.

Wind uplift and/or loads may be further minimized by sealing themounting unit to the roof and angling the rear wall with respect to thebase. This may facilitate in directing winds, such as northerly winds,up and over the mounting unit and/or solar panel. When coupled with asolar panel, the mounting surface may extend beyond the solar panel bybetween about 1 and 10 inches and more commonly about 2 inches. This maylimit the amount of wind that can get under the solar panel and generateadditional wind loads. While embodiments of the invention have beengenerally described, additional features will be evident with referenceto the figures.

Mounting Unit Embodiments

Referring now to FIGS. 1 and 3A-6C, shown are various views of amounting unit 100 configured to couple with a solar panel 170 in orderto mount the solar panel to a roof (e.g., 190 of FIGS. 5 and 6B) of astructure, such as a home or building. Mounting unit 100 includes a base102 that defines a lower periphery of mounting unit 100. Base 102includes a flange 103 that laterally extends from mounting unit 100.Flange 103 may be a single structure that extends around the entirelower periphery of mounting unit 100, or, in some embodiments, flange103 may only extend partially around mounting unit 100 and may includeseveral flanges members or components. As shown in FIG. 1, flange 103extends laterally about 2 to 4 inches from the mounting unit 100 aroundthe entire lower periphery. In other embodiments, flange 103 maylaterally extend more or less than this amount from mounting unit 100(e.g., between about 0.5 and about 6 inches). Flange 103 may distribute,preferably evenly or uniformly, a load (e.g., the weight) of themounting unit 100 and attached solar panel 170 across an area of roof190. Flange 103 may also provide a relatively flat surface to which aflexible membrane 130 or other material may attach. One advantage ofusing flange 103 is that the mounting unit 100 and solar panel 170 loadis distributed across an area the roof's surface, thereby minimizingconcentrated or point loads. In some embodiments, however, base 102 maynot include a flange and may instead include an edge, one or morecontact points or components (e.g., feet), a plurality of elongatesupport members, and the like.

Flange 103 is connected to a plurality of walls around the periphery ofmounting unit 100. Specifically, flange 103 connects with a front wall110, a rear wall 112, and left and right walls, 108 and 106,respectively. As shown in FIG. 3A, rear wall 112 may be oriented at anangle, θ₁, with respect to base 102 or flange 103 so as to minimizeuplift and/or wind loads exerted on mounting unit 100 and the attachedsolar panel 170 by directing air up and over mounting unit 100 and/orattached solar panel 170. In some embodiments, θ₁ may be angled betweenabout 95 degrees and about 135 degrees, and more commonly about 100degrees, with respect to base 102 or flange 103. Front surface 110 maysimilarly be oriented at an angle, θ₂, with respect to base 102 orflange 103 to minimize uplift and/or wind loads. θ₂ may be between about90 degrees and about 135 degrees, and more commonly about 95 degrees,with respect to base 102 or flange 103. As shown in FIG. 3B, right wall106 and left wall 108 may similarly be oriented at an angle, θ₄, withrespect to base 102 or flange 103 to likewise minimize uplift and/orwind loads. θ₄ may be between about 90 degrees and about 135 degrees,and more commonly about 94 degrees, with respect to base 102 or flange103.

Mounting unit 100 also includes a top structure or mounting surface 104connected with walls, 106, 108, 110, and 112. Mounting surface 104 iselevated above base 102 so that the attached solar panel 170 is elevatedabove the roof's surface 190. As shown in FIG. 3A, mounting surface 104may be oriented at an angle θ₃ with respect to base 102 or flange 103.In some embodiments, θ₃ may be between about 0 degrees and about 30degrees, and more commonly about 10 to 15 degrees, with respect to base102 or flange 103. θ₃ may be angled such that the attached solar panel170 is directed or angled toward sunlight incident on the roof's surface190, thereby increasing energy production or generation. θ₃ may also beuseful for promoting drainage and/or self-cleaning via rain runoff ofmounting unit 100 and solar panel 170. This design (i.e., θ₃ angled tosome degree) may be especially useful in application involvingsubstantially flat or low slope roofs (e.g., 3-in-12 pitch or less),such as those commonly used in many commercial buildings. In otherembodiments, θ₃ may be minimal so that mounting surface 104 issubstantially parallel with base 102 or flange 103. This design may beuseful in high slope roofs, such as those commonly used for homes orother buildings.

Mounting unit 100 illustrated in FIGS. 1 and 3A-6C comprises a singlehollow device. The use of a single hollow component for mounting unit100 may provide rigidity and added structure to the mounting unit 100.Further, the hollow interior of mounting unit 100 may allow individualunits to be stacked for compact storage and/or transport. In otherembodiments mounting unit 100 may include multiple pieces or componentsthat couple together and/or may include various openings or openregions. For example, walls 106, 108, 110, and 112, and/or mountingsurface 104 may be a frame having various longitudinally andtransversely extending elements or members that define the walls andmounting surface. Mounting unit 100 may be made from a reinforced orun-reinforced plastic, such as polyethylene, polypropylene, styrene,polyvinyl chloride, and the like and may be formed via a vacuum formingprocess, injection molding process, and the like. In one embodiment, theweight of the mounting unit may be between about 10 and about 17 pounds,and more commonly about 12 pounds. Mounting unit 100 includes variousribs 126, radiuses, draft angles, thin walls, and/or mounting hardware(e.g., mounting channel 150) that provide a rigid yet lightweightstructure. In some embodiments, mounting unit 100 may have alongitudinal length of between about 55 inches and about 70 inches, andmore commonly between about 60 and 65 inches, to accommodate a singlesolar panel in a variety of sizes. Likewise, mounting unit 100 (ormounting unit 200) may have a transverse length of between about 45inches and about 65 inches, and more commonly between about 50 and 60inches.

As described previously, mounting surface 104 and one or more of thewalls 106, 108, 110, and 112 may include one or more ribs, 126 and 127,respectively. The ribs, 126 and 127, may provide structural rigidity formounting unit 100 and may also define channels that allow air to flowunderneath and access a bottom surface of the attached solar panel 170so as to provide passive ventilation and/or convection cooling of thesolar panel and enhance electricity production. Put another way, ribs126 and/or 127 may enable air convection from the lower front wall 110to the higher rear wall 112 to remove heat from the under surface ofsolar panel 170 (i.e., the surface facing mounting surface 104). Thechannels defined by the ribs, 126 and 127, may also allow wind pressureto be equalized under the solar panel 170 by allowing air to flow aroundand over solar panel 170 and between solar panel 170 and mountingsurface 104.

In some embodiment, the channels defined by ribs, 126 and/or 127, may benarrow and may extend fully or partially from front surface or wall 110to rear surface or wall 112. In other embodiments, a combination oftransversely extending and longitudinally extending channels may beused. The channels may be between about 0.25 inches and 3 inches wide,and more commonly about 1 inch wide, and may be between about 0.25inches and about 3 inches deep, and more commonly about 1 inch deep.Additionally, in some embodiments, mounting unit 100 may include one ormore apertures or holes through one or more of walls 106, 108, 110, and112 for wind pressure equalization and/or water drainage.

Mounting surface 104 also include one or more main channels that aresized wider and/or deeper than the channels defined by ribs 126 and/or127. For example, mounting surface 104 is shown having onelongitudinally extending main channel 124 that extends from left surfaceor wall 108 to right surface or wall 106, and shown having twotransversely extending main channels 122 that each extend from frontwall 110 to rear wall 112. In other embodiments, mounting surface 104may include more or less main channels than those shown, which may eachextend partially or fully between the various walls. Main channels, 122and 124, may be used to route electrical cables and wires 180 thatcouple with solar panel 170 as shown in FIG. 6C. For example, electricalwires 180 may be routed from solar panel 170 through longitudinallyextending main channel 124 and coupled with another solar panel (andmounting unit) positioned adjacent solar panel 170 and/or with anotherdevice, component, unit, and the like. Electrical wires and cables 180may likewise be routed or run along transversely extending main channels122 and coupled with adjacent solar panels, components, devices, units,and the like. In this manner, a grid or array of solar panels andmounting units may be coupled together atop a structure of building'sroof to form a photovoltaic power generation system.

In some embodiments, main channels, 122 and/or 124, may be between about2 inches and 6 inches wide, and more commonly about 4 inches wide, andmay be between about 0.5 inches and about 3 inches deep, and morecommonly about 1.25 inches deep. Main channels, 122 and/or 124, maylikewise allow air to flow underneath and access the underside of solarpanel 170 and thereby provide the benefits described above (e.g., windpressure equalization, convection cooling, and the like). The deeper andwider main channels, 122 and 124, may allow air to easily passunderneath solar panel 170 and/or between solar panel 170 and mountingsurface 104. In some embodiments, wind or air may flow underneath solarpanel 170 through main channels, 122 and 124, and exit from underneathsolar panel 170 through the narrow channels defined by ribs 126 toequalize wind pressure and/or cool solar panel 170.

Mounting unit 100 may also include a ground channel 128 within which agrounding lug or component (not shown) of solar panel 170 (or coupledtherewith) may be positioned. The grounding lug or component (not shown)may be electrically coupled with an electric ground within groundchannel 128. In some embodiments, ground channel 128 is positionedsubstantially centrally along rear wall 112 of mounting unit 100,although any other position may be possible.

Mounting unit 100 further includes one or more mounting feature orcomponents 150 that allow mounting unit 100 to releasably couple withsolar panel 170. In one embodiment, mounting unit 100 includes amounting feature or component 150 positioned in each of four corners, asshown in FIGS. 1 and 3A-6C. As shown in the enlarged section A of FIG.1, mounting feature 150 includes an insert 152 positioned and heldwithin mounting surface 104. Mounting feature 150 may be configured(e.g., via edges or flanges 156) to prevent insert 152 from beingwithdrawn from mounting surface 104 in a direction normal to mountingsurface 104. The insert 152 may be inserted into the mounting surface104 after the mounting unit 100 is formed (e.g., via vacuum forming,injection molding, and the like), or may be integrated into the mountingsurface 104 during the forming process, such as by positioning theinsert or multiple inserts 152 in a mold and forming the mounting unit100 onto or over insert(s) 152. Integrating the insert(s) 152 withmounting unit 100 in this manner may provide a more secure attachmentwith the mounting surface 104 and mounting unit 100. In some embodimentsan insert 152 is not included and a pair of edges or flanges 156 ofmounting feature 150 form an inverted T slot that provides the solarpanel 170 mounting functions described below.

Insert 152, or alternatively edge pair 156, is shaped to receive afastener 160 (see FIGS. 1A, 6A, and 6B) that secures solar panel 170 tomounting surface 104. Fastener 160 may include a bolt, pin, nail, screw,clip, button, magnetic member, and the like. Insert 152, oralternatively edge pair 156, has an inverted T-shaped cross section thatdefines a channel 154 within which fastener 160 is inserted. A pair offlanges 158 of insert 152, or alternatively edge pair 156, contactfastener 160 and prevent the fastener 160 from being withdrawn in adirection roughly normal or orthogonal to mounting surface 104. Forexample, fastener 160 may be a bolt that is slidingly inserted withinchannel 154 so that the bolt head is positioned under flanges 158, oredge pair 156. Flanges 158 contact the bold head and prevent removal ofthe bolt in a direction normal to mounting surface 104. Flanges 158 maysimilarly contact an enlarged feature or component of a pin, nail,screw, clip, button, magnetic member and the like to prevent removal ofthose fasteners in a direction normal to mounting surface 104. Insteadof channel 154, insert 152 may include a plurality of longitudinallyarranged apertures (not shown) through which fastener 160 is positioned,threaded, and/or locked. Fastener 160 may be longitudinally positionedwith respect to insert 152, and thus mounting surface 104, bypositioning, locking, or threading fastener 160 within a respectiveaperture. One advantage of channel 154 is that the fastener 160 mayslide partially or fully along the length of insert 152, which allowsfastener 160 to be longitudinally positioned virtually anywhere alonginsert 152 and thereby allows mounting unit 100 to accommodate andcouple with a wider variety of solar panels sizes.

As shown in FIGS. 6A and 6B, fastener 160 may extend roughly normallyfrom mounting surface 104 when positioned within insert 154. Fastener160 couples with mounting hardware 172 of solar panel 170 to securesolar panel 170 to mounting unit 100. Mounting hardware 172 may includea Z profile mounting plate having an aperture (not shown) through whichfastener 160 is inserted. A nut can then be threaded onto the bolt, orfastener 160 may otherwise be secured, to secure mounting hardware 172(e.g., Z profile plate) to mounting surface 104. FIG. 6C illustratessolar panel 170 having a plurality of solar or photovoltaic cellssecured atop mounting surface 104 of mounting unit 100 and mounting unit100 secured to roof surface 190. As shown, mounting surface 104 mayextend beyond solar panel 170 by an amount, B, which may be betweenabout 1 and 10 inches and more commonly about 2 inches (amount B mayvary between the longitudinal and transverse directions). This designmay limit the amount of wind that can get under solar panel 170 andgenerate additional wind loads.

As mentioned previously, a flexible membrane or skirt 130 is coupledwith mounting unit 100 to secure mounting unit 100 to the surface ofroof 190. Flexible membrane or skirt 130 may extend around a portion orthe entire periphery of base 102 and may be bonded to an underside offlange 103 or base 102 so that flexible membrane 130 extends laterallybeyond flange 103 or base 102 a distance D of between about 1 inch andabout 6 inches, and more commonly about 2 inches. In some embodiments,flexible membrane 130 may similarly extend in an opposite directionlaterally into an interior of mounting unit 100 up to between about 1inch and about 6 inches, and more commonly by about 2 to 4 inches. Insome embodiments, flexible member 130 may include a solid membrane thatspans the interior portion of mounting unit 100, although suchembodiments may not allow individual mounting units to be stacked forconvenient storage and/or transport as described herein. An interiorportion of the solid member may be removed to allow the individual unitsto be conveniently stacked. Flexible membrane or skirt 130 may furtherhelp distribute the loads across the roof's surface to prevent orminimize concentrated or point loads.

As shown in FIG. 4, flexible membrane 130 may include multiple segmentsor strips sized roughly to correspond with a respective side of mountingunit 100 and positioned around the periphery of base 102. In anotherembodiment, flexible membrane 130 may include a single strip or piecethat extends around the periphery, or may include multiple unconnectedsegments or strips (not shown) that are coupled with one or more sidesof mounting unit 100. Flexible membrane 130 may be heat welded,adhesively bonded, mechanically fastened (e.g., via rivets, pins,clamps, and the like), and the like to the underside of flange 103 orbase 102. Flexible membrane 130 may be made of roofing membranematerials such as: Thermo Plastic Olefin (TPO), Ethylene Propylene DieneMonomer (EPDM), Polyvinyl Chloride (PVC), thermoplastic vulcanizates(TPV), and the like. In one embodiment, the flexible membrane includes aTPO material with a polyester fleece attached to the bottom surface.

Flexible membrane or skirt 130 may function as a protective layerbetween flange 103 or base 102 and the roof surface 190 to prevent orlimit motion between base 102 or flange 103 and the roof surface 190that could otherwise result in roof penetrations and eventual leakage.The flexibility of membrane 130 may allow the membrane or skirt tocompensate for small variations in the roof's surface 190, therebyfunctioning to ensure a firm and continuous bond between mounting unit100 and the roof's surface 190. For example, flexible membrane 130 mayflex or bend into or around creases, seams, bends, dips, and the like ofroof surface 190 and bond with such uneven surfaces. Likewise, membraneor skirt 130 may conform to and bond with rough or gritty surfaces ofthe roof, such as asphalt or gravel roofs. The polyester fleece attachedto the bottom of the membrane may enable mounting unit 100 to beadhesively bonded to such rough or gritty surfaces by absorbing liquidadhesives that bond with such surfaces. The flexibility of membrane orskirt 130 allows a portion or the entire periphery of mounting unit 100to be sealed against the roof surface 190.

To secure mounting unit 100 to the roof, flexible membrane or skirt 130couples with a membrane material of the roof, which may include ThermoPlastic Olefin (TPO); Ethylene Propylene Diene Monomer (EPDM); PolyvinylChloride (PVC); thermoplastic vulcanizates (TPV), ChlorosulfonatedPolyethylene (CSPE), Co-polymer Alloy (CPA), Chlorinate Polyethylene(CPE), Ethylene-interpolymer (EIP), Nitrile Butadiene Polymer (NBP),Polyisobutylene (PIB), Keytone Ehtylene Ester (KEE), Modified Bitumen,and the like. Flexible membrane or skirt 130 may be coupled with theroof membrane via an adhesive, tape, heat welding, mechanical fasteners,and the like. For example, as shown in FIG. 5, a tape 140 may bepositioned over flexible membrane or skirt 130 and roof surface membrane190 and pressed onto those surfaces to secure and/or seal mounting unit100 to the roof and/or to provide weatherproofing to an adhesivelymounted mounting unit 100. Tape 140 may be placed around a portion orthe entire periphery of the mounting unit 100. Alternatively oradditionally, the portion of flexible membrane or skirt 130 laterallyextending beyond base 102 or flange 103 may be heat welded to roofsurface membrane 190 around a portion or the entire periphery of themounting unit 100. For example, mounting unit 100 may be positionedagainst roof surface 190 and a heat welder or other device may be movedaround the periphery of mounting unit to apply heat and/or pressure tothe laterally extending flexible membrane 130 and the roof membrane soas to heat weld the membranes together. Flexible membrane or skirt 130may likewise be adhesively bonded or mechanically fastened (e.g., viarivets and the like) to roof surface membrane 190 around a portion orthe entire periphery of the mounting unit 100.

The type of fastening employed may depend on the membrane material ofthe roof 190 and/or skirt 130. For example, heat welding may be use tocouple similar membrane materials of the skirt 130 and roof 190 (e.g.,to couple a TPO skirt to a TPO roof membrane). Adhesives, mechanicalfasteners, and/or tape 140 may be used to couple dissimilar membranematerials of the skirt 130 and roof, such as using polyester fleece andadhesives to couple skirt 130 to gravely or asphalt roofs and usingadhesives to couple skirt 130 having membrane polymer A (e.g., TPO) toroof 190 having membrane polymer B (e.g., EPDM). Similarly, the membranematerial used for skirt 130 may be selected based on the roof's membraneand the fastening method desired. For example TPO may be selected forthe skirt 130 when heat welding is desired and roof 190 includes a TPOmembrane. One advantage of coupling membrane or skirt 130 with theroof's membrane 190 using heat welding, adhesives, or tape is thataperture, holes, or other penetrations are not formed/created orminimally formed/created in the roof's membrane. This minimizes oreliminates water, air, and/or other leakage through the roof's membraneand the resulting problems associated therewith. Another advantage ofusing heat welding, adhesives, or tape to bond membrane or skirt 130with roof surface 190 is providing a tight seal around a portion or theentire periphery of the mounting unit 100.

Flexible membrane or skirt 130 allows mounting unit 100 to easily couplewith various types of roof surfaces. Flexible membrane or skirt 130further allows mounting unit 100 and attached solar panel 170 to beeasily removed from roof's surface 190 and positioned in another area ofthe roof's surface or on a different roof's surface. For example,flexible membrane 130 may be removed from mounting unit 100 so thatmounting unit 100 and attached solar panel 170 may be uncoupled from theroof, moved to a different area or different roof, fitted with anothermembrane or skirt 130, and reattached to the roof's surface.

Referring now to FIG. 2, illustrated is another embodiment of a mountingunit 200 having a longitudinally extended front wall 210 and rear wall222 such that two solar panels (not shown) may be adjacently coupledatop a mounting surface 204 of mounting unit 200. Mounting unit 200 maybe approximately twice the longitudinal length of mounting unit 100 toaccommodate to solar or photovoltaic panels or modules. Mounting unit200 may include various feature or components similar to those describedabove for mounting unit 100 including: mounting features 250, ribs 226that define narrow channels, main channels 222 and/or 224, side walls206 and 208, ground channels 228, a flange 203, a membrane or skirt 230,and the like.

Conduit for Mounting Units

Referring now to FIGS. 7A-7C illustrated is a conduit 194 that may beused to connect the main channels of adjacent mounting units so as toroute electrical wires or cables between adjacent mounting units andsolar panels. Specifically shown is a mounting unit 200 positionedbehind mounting unit 100. Conduit 194 is positioned within a recess 292on the front wall 210 of mounting unit 200 and within a recess 192 onthe back wall 112 of mounting unit 100. As shown in FIGS. 1 and 3C, eachmain channel 122 (or 222) may include a recess 192 that conduit 194releasably snaps and locks into. Electrical wires or cables, such aswires 180 may be routed through conduit 192 between adjacent mountingunits so as to prevent or limit exposure of the wires to variousenvironmental or other conditions. Conduit 192 may be telescoping so asto be longitudinally adjustable to accommodate various mounting unitarrangements and spacing. To provide the telescoping feature, conduit192 may include a first tube slidingly disposed within a second tube.

As shown in FIG. 7C, which is a side view of the mounting units of FIG.7B cut along line A-A, recesses 192 and 292 of mounting units 100 and200, respectively, may be positioned with respect to rear wall 112 andfront wall 210, respectively, such that a spacing F exists betweenopposite ends of conduit 194 and the respective front and rear walls,210 and 112. Spacing F may allow one or more wires 180 to be routedalong main channel 222, into a distal end of conduit 194, out of aproximal end of conduit 194, and along main channel 122.

Exemplary Methods

Referring now to FIG. 8, illustrated is a method 800 of mounting a solaror photovoltaic panel to a roof of a structure, such as a home or abuilding. At block 810 a mounting unit is provided or obtained. Asdescribed herein, the mounting unit may include a base and/or flange, amounting surface, and a plurality of walls that connect the mountingsurface to the base in an elevated and/or angled fashion. The mountingunit may also be designed to couple with a single solar panel ormultiple solar panels as described herein. At block 820, a flexiblemembrane or skirt may be coupled with the base and/or flange. Couplingthe flexible membrane or skirt with the base and/or flange may includeheat welding, adhesive bonding, mechanical fastening, and the like. Atblock 830, the flexible membrane or skirt may be coupled with a surfaceof the roof to secure the mounting unit to the roof. Coupling theflexible membrane or skirt with the roof surface may include heatwelding, adhesive bonding (e.g., adhesive and/or tape), mechanicalfastening, and the like. At block 840, a solar panel may be coupled witha mounting surface of the mounting unit. Coupling the solar panel withthe mounting surface may include inserting a bolt within a mountingchannel of the mounting surface, positioning the bolt through anaperture of a mounting feature of the solar panel, and securing the boltwith respect to the solar panel. The mounting channel may be configuredto prevent removal of the bolt in a direction substantially normal tothe mounting surface and may comprise an inverted T shape slot asdescribed herein.

The method may also include positioning one or more electrical wires ofthe solar panel within a main channel of the mounting surface so as toelectrically couple the solar panel with one or more other devices. Theone or more other devices may include an additional solar panel, a powerdevice, a control device, a DC/DC optimization device, a combiner box, adisconnect switch, a breaker, fuses, a power inverter, and the like.

Exemplary Mounting Unit Configuration

In some embodiments, the flexible membrane material or skirt(hereinafter flexible membrane material) may be coupled with only aportion of the mounting unit's flange rather than around the entireperiphery. This configuration may enable the mounting unit to be quicklyand easily coupled with a roof while providing sufficient holdingstrength for the mounting unit. For example, the mounting unit may notneed a flexible membrane material to be positioned around the entireperimeter in order to secure the mounting unit to the roof. Positioningthe flexible membrane material around less than the entire perimeter mayspeed up the installation process since an installer is not required toheat weld or otherwise bond or couple all four sides of the mountingunit to the roof.

FIG. 9A illustrates one embodiment of such a mounting unit. The mountingunit of FIG. 9A is similar to those previously described in that themounting unit includes a base 902 that is configured for positioningatop a roof. The base 902 includes flanges 910 that are positionedaround the perimeter or periphery of the base 902 and that extendlaterally therefrom. In some embodiments, the base 902 may include onlya few flange sections (i.e., a front flange and a rear flange) ratherthan a flange that extends around the entire perimeter or periphery ofbase 902. As shown in FIGS. 9B and 9C, a mounting surface 912 ispositioned above the base 902 via walls that connect the mountingsurface 912 and the base 902 as previously described. The mountingsurface 912 is configured to couple with a solar panel to elevate thesolar panel above a surface of the roof and to orient the solar panel atan angle relative to the roof.

A flexible membrane material 904 is coupled or attached to one of theflanges 910 of base 902. The flexible membrane material 904 is attachedto the flange 910 so as to extend laterally therefrom. As shown in theembodiment of FIGS. 9A-9C, the flexible membrane material 904 may beattached to a rear flange 910 of the base 902, although in otherembodiments, the flexible membrane material 904 may be coupled withanother one of the base's flanges and/or with multiple flanges. Animportant aspect of the embodiments of FIGS. 9A-9C is that the flexiblemembrane material 904 is coupled or attached with fewer than all of thebase's flanges 910. Stated differently, the base 902 includes flanges910 that do not include, or are otherwise free of, a flexible membranematerial 904. Rather, an adhesive or tape material 906 is applied to anunderside or bottom surface of one or more of those flanges that do notinclude the flexible membrane material 904. As shown in FIG. 9A, a frontflange and two opposing side flanges 910 are each free of, or otherwisedo not include, the flexible membrane material 904, but include anadhesive or tape material 906 applied to the bottom surface of theflanges 910.

This configuration—i.e., having at least one flange with the flexiblemembrane material 904 and at least one flange with an adhesive/tape 906rather than the flexible membrane material 904—allows an installer toquickly and conveniently couple the mounting unit with a roof. Forexample, as shown in FIG. 9C, an installer merely needs to couple thesingle flexible membrane material 904 with the roof and the mountingunit can be pivoted about the coupled flexible membrane material 904.The installer may then easily remove a film that is applied over theadhesive or tape 906 and pivot the mounting unit downward so that theadhesive or tape 906 contacts the roof's surface to adhesively bond themounting unit with the roof. The film applied to the adhesive or tape906 may prevent or limit degradation of the adhesive material prior toadhering the adhesive or tape 906 with the roof.

In a specific embodiment, the mounting unit includes only a singleflange having the flexible membrane material 904, such as the rear orback flange shown in FIGS. 9A-9C. In such an embodiment, one or more ofthe other flanges, and in a specific embodiment the other three flanges,include the adhesive or tape 904. The configuration enables quickinstall of the mounting unit since the flexible membrane material 906attached to the rear flange may be coupled with the roof and then themounting unit pivoted upward and downward to remove a film from theadhesive or tape 904 and to apply the adhesive or tape to the roofsurface.

As shown in FIG. 9A, in some embodiments, at least one portion orsegment of the adhesive or tape 906 includes a gap 908. In theembodiment illustrated of FIG. 9A, the adhesive or tape 906 includes twogaps 908 that are positioned near opposing sides of the base. The gap(s)908 may be formed from the adhesive or tape 906 that is positioned onthe front flange of the mounting unit, such as by extending the adhesiveor tape 906 along less than the entire edge of the front flange. Thegap(s) 908 may likewise be formed in or along any of the mounting unit'sother sides. The gaps(s) 908 may promote drainage of water or otherfluids by providing a channel through which the fluid may drain. Thegap(s) 908 help prevent accumulation and stagnation of water or otherfluids within the mounting unit and under an attached PV module.

In some embodiments, the adhesive or tape 906 may not extend from beyondan edge of the mounting unit's flange. Rather, the adhesive or tape 906may extend substantially up to, or slightly retracted from, the flange'sedge. In contrast, the flexible membrane material 904 typically doesextend beyond the flange's edge in order to allow a heat weldingmachine, or other machine, to bond the flexible membrane material 904with the roof. Exemplary adhesives or tapes include butyl, acrylic,and/or polyurethane-based adhesives or tapes, that may or may not bepressure-sensitive, suitable for exterior use in roofing-typeapplications.

According to one embodiment, a method of attaching a solar panelmounting unit to a roof includes providing a solar panel mounting unithaving: a base that includes a first flange and a second flange thatextend laterally from the base; a mounting surface positioned above thebase via walls that connect the mounting surface and the base, themounting surface being couplable with a solar panel to elevate the solarpanel above a surface of the roof and angle the solar panel relativethereto; a flexible membrane coupled with the first flange of the baseand extending laterally therefrom; and an adhesive or tape applied to anunderside of the second flange, the second flange being free of theflexible membrane material. The method also includes coupling theflexible membrane material with the roof to secure the solar panelmounting unit to the roof and adhesively bonding the adhesive or tapewith the roof to additionally secure the mounting unit to the roof. Asdescribed above, the flexible membrane material may be initially bondedor coupled with the roof and the mounting unit pivoted upward to removea polymeric or other film from the adhesive or tape. The mounting unitmay then be pivoted downward and into contact with the roof to adherethe adhesive or tape with the roof.

As described above, the flexible membrane material and/or adhesive/tapemay be coupled with the mounting unit in a variety of configurations.For example, in some embodiments the method may include coupling theflexible membrane material with only the first flange of the base (e.g.,toward the rear of the base) and applying the adhesive or tape with anunderside of at least one other flange of the base (e.g., the secondflange), such as the front and/or side flanges. In some embodiments, themethod may also include forming a gap or gaps in at least one portion orsegment of the adhesive or tape, such as near the front flange and onopposite sides of the front flange. The method may additionally includeheat welding the flexible membrane material to the roof and removing afilm from the adhesive or tape prior to adhesively bonding the adhesiveor tape with the roof. The film may prevent or limit degradation of anadhesive material. In some embodiments, an adhesive or tape may be usedto bond the flexible membrane material to the roof rather than heatwelding the flexible membrane material to the roof. This approach may bepreferred in applications that involve rubber roof materials, such asEPDM, since the flexible membrane material (e.g., TPO) may not be heatweldable to such roofing materials. In such embodiments, the flexiblemembrane material may be heat welded to the a flange of the base, suchas toward the rear of the base, but the flexible membrane material wouldbe taped or adhered to the roof surface.

Exemplary Mounting Methods

Referring now to FIGS. 15A and 15B, illustrated are embodiments showinga specific method of mounting adjacent mounting units. As shown in FIG.15A, according to one embodiment, a first mounting unit 1502 may beattached to a roof, such as using the method described above. Forexample, a flexible membrane material 1506 positioned on a rear surfaceof the first mounting unit 1502 may be heat welded to the roof. A frontedge 1508 of a second mounting unit 1504 may then be positioned over andadhered to the flexible membrane material 1506 of the first mountingunit 1502. The front edge 1508 of the second mounting unit 1504 includesan adhesive or tape having a film that is removed as previouslydescribed prior to adhering the front edge 1508 with the flexiblemembrane material 1506. In coupling the first and second mounting units,1502 and 1504, the second mounting unit 1504 may be pivoted upward anddownward to adhere the front edge 1508 with the flexible membranematerial 1506 and to remove the film from the adhesive or tape. FIG. 15Billustrates the two mounting unit coupled together with the front edge1508 of second mounting unit 1504 overlapping 1510 the flexible membranematerial 1506 of first mounting unit 1502.

According to one embodiment, the coupling method described above mayfurther include aligning a plurality of mounting units atop a roof by:coupling a flexible membrane material of a first mounting unit with theroof, positioning a front flange of a second mounting unit atop theflexible membrane of the first mounting unit, and adhesively bonding—viathe adhesive or tape—the front flange of the second mounting unit withthe flexible membrane of the first mounting unit.

The above described longitudinal spacing of adjacent mounting units,where the front flange of one mounting unit overlaps the adjacentflexible membrane material or skirt of the adjacent mounting unit,allows for increased roof power density. For example, for every 27-36rows with this overlapping configuration, another row of mounting unitscan be placed onto a roof, thereby increasing the power density of theroof by roughly 3-4%, depending on the exact amount of overlap. As such,the power generated by mounted solar panels is increased, which lessensthe dependence of the structure or building on external power sources,such as coal or other power sources, that may contribute to climatechange.

Exemplary Spacing Jig

Referring now to FIGS. 14A-14D, illustrated are embodiments of spacingmembers or apparatus (hereinafter spacing jig) that may be used to spacemounting units atop a roof. The spacing jig 1400 of FIG. 14A may be usedto longitudinally space the mounting units while the spacing jig 1420 ofFIG. 14B may be used to laterally space the mounting units.

Referring first to the spacing jig of FIG. 14A, the spacing jig 1400includes a first longitudinal member or section 1402 and a secondlongitudinal member or section 1404 that is coupled with the firstlongitudinal member 1402 at an angled orientation relative thereto. Thefirst and/or second members, 1402 and 1404, may include tubing having asquare, circular, or other cross section. The first member 1402 includesa pivot member 1408 that is pivotally attached to a proximal end of thefirst member 1402. The pivot member 1408 includes a first tab or flange1410 that may be positioned within a corresponding groove of a firstmounting unit 1440 as shown in FIG. 14C. The groove of the firstmounting unit 1440 may be a T shaped slot as described herein that ispositioned near the front surface of the first mounting unit 1440.

The second member 1404 is coupled with the distal end of the firstmember 1402 so as to form an angle relative thereto. As shown in FIG.14A, the first and second members, 1402 and 1404, may form a roughly 90degree angle or any other angle desired, such as between 45 and 135degrees. The second member 1404 may be telescopingly inserted within athird member 1406 that is directly attached to the distal end of firstmember 1402 or integrally formed therewith. The second member 1404 maybe telescopingly elongated or shortened by sliding the second member1404 within the third member 1406 as desired. The third member mayinclude a plurality of apertures and the second member may include aplurality of detents to hold or maintain the two members in a desiredelongated or shortened configuration. A second tab or flange 1412 ispositioned on the distal end of the second member 1404. The secondflange 1412 may be positioned within a corresponding groove of a secondmounting unit 1430 as shown in FIG. 14C. The groove of the secondmounting unit 1430 may be a T shaped slot as described herein that ispositioned near the rear surface of the second mounting unit 1430.Positioning of the first flange 1410 within the first mounting unit1440's slot and the second flange 1412 within the second mounting unit1440's slot longitudinally aligns the two mounting units in a front toback orientation.

According to one embodiment, the above described method may furtherinclude positioning a first mounting unit 1440 atop the roof andpositioning a second mounting unit 1430 atop the roof. The first flange1410 of the spacing jig 1400 may be positioned within a slot of thefirst mounting unit 1440 and the second flange 1412 of the spacing jig1400 may be positioned within a slot of the second mounting unit 1430.Said positioning of said first and second flange members, 1410 and 1412,within said respective slots said first and second mounting units, 1440and 1430, longitudinally aligns said mounting units. To insert orposition the second flange 1412 within the slot of the second mountingunit 1430, the spacing jig 1400 may be pivoted downward relative to themounting units and into position via pivot member 1408. The secondmember 1404 may be slid within or with respect to the third member 1406to achieve a desired spacing prior or subsequent to inserting saidflanges members within said respective slots of said mounting units. Insome embodiments, a pair of spacing jigs 1400 may be used to space theadjacent units.

Referring now to the spacing jig 1420 of FIG. 14B, the spacing jig 1420includes a first longitudinal member or section 1422 and a secondlongitudinal member or section 1424 that is telescopingly disposedwithin the first longitudinal member 1402. The first and/or secondmembers, 1422 and 1424, may include tubing having a square, circular, orother cross section. The first member 1422 includes a first tab orflange 1426 that is positioned on a proximal end thereof and that may bepositioned within a corresponding groove of a first mounting unit 1440as shown in FIG. 14D. The first flange 1426 may be oriented roughlyorthogonal to the first member 1422 to facilitate positioning of theflange 1426 within the groove of the first mounting unit 1440. Thegroove of the first mounting unit 1440 may be a T shaped slot asdescribed herein that is positioned near a side edge of the firstmounting unit 1440.

The spacing jig 1420 may be telescopingly elongated or shortened bysliding the first member 1422 within the second member 1424. The secondmember 1424 may include a plurality of apertures and the first member1422 may include a plurality of detents to hold or maintain the twomembers in a desired elongated or shortened configuration. In someembodiments, the adjustment of the two members may utilize aspring-loaded push button or a set screw for continuous (i.e., minimallysmall) adjustment increments.

A second tab or flange 1428 is positioned on a distal end of the secondmember 1424. The second flange 1428 may be positioned within acorresponding groove of a second mounting unit 1430 as shown in FIG.14D. The groove of the second mounting unit 1430 may be a T shaped slotas described herein that is positioned near a side edge of the secondmounting unit 1430. The second flange 1428 may be oriented roughlyorthogonal to the second member 1424 to facilitate in positioning of thesecond flange 1428 within the groove of the second mounting unit 1430.Positioning of the first flange 1426 within the first mounting unit1440's slot and the second flange 1428 within the second mounting unit1440's slot longitudinally aligns the two mounting units in a side toside orientation.

According to one embodiment, the above described method may furtherinclude positioning a first mounting unit 1440 atop the roof andpositioning a second mounting unit 1430 atop the roof. The first flange1426 of the spacing jig 1420 may be positioned within a slot of thefirst mounting unit 1440 and the second flange 1428 of the spacing jig1420 may be positioned within a slot of the second mounting unit 1430.Said positioning of said first and second flange members, 1426 and 1428,within said respective slots of said first and second mounting units,1440 and 1430, laterally aligns said mounting units. The first member1422 may be slid within or with respect to the second member 1424 toachieve a desired spacing prior or subsequent to inserting said flangesmembers within said respective slots of said mounting units. As shown inFIG. 14D, a pair of spacing jigs 1420 may be used to space the adjacentunits.

Exemplary Reinforced T-Slots

In some instances it may be desirable to reinforce the slots or grooves(i.e., the previously described mounting feature 150) of the mountingunit. The slots or grooves described in the embodiments herein below mayhave a configuration to those previously described—i.e., the previouslydescribed mounting feature 150. Specifically, the slots or grooves mayhave an inverted T shape configuration that is shaped and sized toaccommodate a separate coupling component or member that couples withthe solar panel or PV module. For ease in describing the embodiments,the slots will be referred to generally as slots or T-slots. Reinforcingthe slots of the mounting unit may increase the wind uplift resistanceof the unit. For example, the reinforced slots may prevent or limit anattached solar panel from pulling or tearing through the slots of themounting unit. The reinforced slots may be configured or designed todistribute the load across the mounting unit, which aids in securing thesolar panel more firmly to the mounting unit.

Referring now to FIGS. 10A-11C, illustrated are embodiments in which themounting unit's slots are reinforced. FIGS. 10A-10B illustrate amounting unit 1002 that includes a base, a plurality of walls thatextend upward from the base, and a mounting surface connected with andpositioned above the base via the plurality of walls as previouslydescribed. The mounting surface includes a plurality of slots 1006 thatare each configured to receive a coupling component or mounting railthat facilitates in coupling the solar panel atop the mounting surfaceas previously described. At least one slot 1006, and typically eachslot, is reinforced to more securely couple the solar panel atop themounting unit 1002 and thereby increase the wind uplift resistance ofthe mounting unit. The reinforced slot(s) allow the mounting unit 1002to be installed in areas of the roof that may experience greater windforces and/or in locations that are traditionally windy, such as coastalregions.

FIG. 10A illustrates a bottom plan view of the mounting unit 1002. Toreinforce the slots 1006, a mesh material 1004 is integrally formed intothe mounting surface at each reinforced slot location. The mesh material1004 may be a tape or film that includes fiber reinforcement made fromglass, carbon, Kevlar, or other suitable materials, or any combinationthereof. Preferable, the tape or film 1004 is of a similar chemistry tothe underlying material of the mounting unit 1002, so that thereinforced tape or film 1004 is properly bondable to the base materialof mounting unit 1001 during the thermoforming process or in a separateprocess. In a specific embodiment, the mesh material 1004 (e.g., tape orfilm) is vacuum molded or insert molded into the mounting surface ofmounting unit 1002 at each reinforced slot location 1006. The meshmaterial 1004 may be integrally formed with each slot location 1006and/or may be positioned near a lower or bottom surface of thereinforced slot.

FIG. 10B illustrates a top plan view of the mounting unit 1002. Toreinforce the slots 1006, a mesh material 1014 is attached to a topsurface of the mounting surface at each reinforced slot location 1006.As previously described, the mesh material 1014 may be a tape or filmthat includes fiber reinforcement made from glass, carbon, Kevlar, orother suitable materials, or any combination thereof. The tape or film1014 may be of a similar chemistry to the underlying material of themounting unit 1002. In a specific embodiment, the mesh material or tape1014 is adhesively bonded with the mounting surface's top surface ateach reinforced slot location 1006 subsequent to forming of the mountingunit 1002. As such, the mesh material 1014 may be retrofitted toexisting mounting unit models. In some embodiments, the mesh material ortape 1014 may increase the stiffness of the entire base unit by addingthe reinforced tape to all or part of the mounting surface of the unit1002. The mesh materials of FIGS. 10A and 10B (i.e., mesh material 1004and 1014) help distribute the wind uplift loads about the mounting unit1002 and/or counteract the wind uplift loads via the reinforcing fibers.

FIGS. 11A-11C illustrate a mounting unit 1002 that includes a base, aplurality of walls that extend upward from the base, and a mountingsurface connected with and positioned above the base via the pluralityof walls as previously described. The mounting surface includes aplurality of slots that are reinforced and configured to receive acoupling component or mounting rail as previously described. At leastone of the slots in FIGS. 11A-11C is extended or elongated. The longeror elongated slots help to distribute uplift loads from the solar panelonto a larger area of the mounting unit 1002, which may increase theoverall rigidity of the mounting unit 1002. As shown in FIGS. 11A-11C,the mounting unit 1002 may include one or more elongated slots. Toaccommodate the elongated slots, the mounting unit 1002 may or may notinclude the longitudinally extending main channel 124 and/ortransversely extending main channels 122. The elongated slots reduce thestress induced by wind forces by distributing the load over a greaterarea of the mounting unit 1002, thereby minimizing or eliminating pointloads.

FIG. 11A illustrates a first embodiment where the mounting unit 1002includes a reinforced slot in the form of an elongated slot 1016 thatextends from adjacent a first side 1018 of the mounting unit 1002 toadjacent a second side 1020 of the mounting unit 1002 that is oppositethe first side 1018. The mounting unit 1002 of FIG. 11A also includes asecond similar shaped elongated slot 1016 that is positioned near anopposite side of the mounting unit 1002. The two elongated slots 1016traverse longitudinally along the mounting unit 1002 between the firstside 1018 and the second side 1020. In some embodiments, the opposingends of the elongated slot 1016 may extend to within one inch of theopposing sides, 1018 and 1020, of the mounting unit 1002.

FIG. 11B illustrates a second embodiment of the mounting unit 1002wherein the reinforced slots are in the form of elongated slots 1026.The mounting unit 1002 of FIG. 11B differs from that of FIG. 11A in thatthe elongated slot 1026 traverses laterally across the mounting unit1002 between a first side 1022 and a second side 1024 of the mountingunit 1002. The mounting unit 1002 includes a second similarly shapedelongated slot 1002 that is positioned near the opposite side of themounting unit. In some embodiments, the opposing ends of the elongatedslot 1026 may extend to within one inch of the opposing sides, 1022 and1024, of the mounting unit 1002. FIG. 11C illustrates that the mountingunit 1002 may include a combination of an elongated slot 1026 and ashorter slot 1006 as desired. In a specific embodiment, the elongatedslot 1026 may be positioned near a rear or other edge of the unit thatexperiences greater wind uplift forces.

Other methods of reinforcing the mounting unit's slots may include theuse of a plurality of fasteners, such as hardware clamps and butyl tape,to secure the solar panel to the mounting unit. Other methods ofreinforcing the mounting unit's slots may include forming or moldinggeometric features into the slots that are configured to specificallyincrease the wind uplift resistance. For example, the slots may beformed with a diagonal or cross-hatch pattern that increases the winduplift resistance, such as by distributing wind uplift forces to alarger area of the mounting unit.

According to one embodiment, a method of reinforcing a solar panelmounting unit includes providing a solar panel mounting unit having: abase, a plurality of wall that extend upward from the base, a mountingsurface connected with and positioned above the base via the pluralityof walls, and a plurality of slots that are formed in the mountingsurface and configured to receive a coupling component that facilitatesin coupling the solar panel atop the mounting surface. The method alsoincludes reinforcing at least one of the plurality of slots, andpreferably each slot, so that the reinforced slots exhibit an increasedability to secure the solar panel atop the mounting unit and/or increasethe wind uplift resistance of the mounting unit.

In some embodiments, reinforcing the slots includes integrally forming amesh material into the mounting surface at each slot location, such asby vacuum molding or insert molding the mesh material into the mountingsurface at each reinforced slot location. In other embodiments,reinforcing the slots includes attaching a mesh material or tape to atop surface of the mounting surface at each reinforced slot location,such as by adhesively bonding the mesh material or tape with themounting surface's top surface at each slot location. In yet anotherembodiment, reinforcing the slots includes forming elongated slots inthe mounting surface, where each elongated slot extends from adjacent afirst side of the mounting surface to adjacent a second side of themounting surface that is opposite the first side. In such embodiments,the mounting surface may include two elongated slots that are positionedtoward opposing sides of the mounting unit.

Electrically Conductive Clamps

In some instances it may be desirable to electrically couple any exposedor “dead” conductive pieces or parts of the mounting unit with theattached PV module. Such electrical coupling may be done to ground theexposed conductive pieces and thereby prevent those pieces fromgenerating a large electric potential. The term exposed or “dead”conductive pieces means any material that is capable of generating anelectric potential and that is not connected to ground. Such pieces mayinclude the coupling component or mounting rail (e.g., insert 152) thatis inserted within the slot (e.g., mounting feature 150), or may includeone or more fasteners that attach the mounting unit to the roof and/orthe PV module to the mounting unit. In some embodiments the exposed ordead conductive pieces may be electrically coupled to the PV moduleusing a conductive clamp. The conductive clamp may be made of metal andbe configured specifically to electrically couple the exposed or deadconductive pieces and the PV module. The conductive clamp may functionto both the secure the PV module atop the mounting unit and toelectrically ground or couple the exposed or dead conductive pieces.

FIGS. 12A and 12B illustrate a conductive clamp that may be used toelectrically couple exposed or dead conductive pieces with a PV module.The clamp of FIGS. 12A and 12B may be particularly useful forelectrically coupling a coupling component (e.g., insert 152) with thePV module and may be useful for mounting the PV module. The clamp ofFIGS. 12A and 12B may function similar to the mounting hardware 172described in FIGS. 6A and 6B that couples with fastener 160 to secure asolar panel 170 to the mounting unit 100. The clamp includes a clampbody 1202 having an elongate mid-section, a first end 1206, and a secondend 1204 opposite the first end. The clamp body 1202 is made of anelectrically conductive material, such as aluminum, steel, stainlesssteel, and the like. The first end 1206 of the clamp is configured tocouple with a metallic mounting rail or coupling component (e.g., insert152—hereinafter mounting rail) of the mounting unit (not shown). Incoupling with the mounting rail (not shown), the first end 1206 isconfigured to contact exposed metal of the mounting rail to establishelectrical bonding between the clamp body 1202 and the mounting rail.The second end 1204 is configured to couple with a PV module or solarpanel (hereinafter solar panel) that is positioned atop the mountingunit. The second end 1204 is coupled with the solar panel so that thesecond end 1204 electrically contacts the solar panel and therebyestablishes electrical bonding between the mounting rail and the solarpanel.

The first end 1206 includes a heel or raised portion 1210 that isconfigured to increase the clamp tension between the clamp body 1202 andthe mounting rail, such as by pressing downward atop the mounting rail.In some embodiments, the heel or raised portion 1210 includes a tip,corner, and/or sharp edge that is configured to establish electricalbonding between the clamp body and mounting rail by biting or pressinginto the mounting rail. The first end 1206 may also include an aperture1208 through which a fastener of the mounting rail, such as a bolt, pin,and the like, is inserted to couple the clamp body 1202 with themounting rail. As shown in FIG. 12B, in some embodiments, the second end1204 also includes a bent tip or corner 1212 that is configured topierce oxide or anodization layers on the solar panel's frame in orderto establish electrical bonding between the clamp body 1202 and thesolar panel. The tip or corner 1212 may pierce the solar panel's oxideor anodization layers as the clamp body 1202 is secured to the mountingrail, such as via aperture 1208.

In some embodiments, the mounting unit may not include exposed or deadconductive pieces, such as when a majority or all of the mounting unit'scomponents are made of plastic. In such embodiments, the clamp of FIGS.12A and 12B may be made or reinforced plastic. Producing the clamps fromreinforced plastics eliminates the need to ground exposed metal parts.

According to an embodiment, a method of electrically coupling a solarpanel with one or more components of a solar panel mounting unitincludes providing a solar panel and providing a mounting unit. Themounting unit may include a metallic mounting rail that is configuredfor coupling with the solar panel. The method also includes positioningthe solar panel atop the mounting unit and providing a clamp having anelongate mid-section, a first end, and a second end opposite the firstend where the clamp is made of an electrically conductive material. Themethod further includes coupling the first end of the clamp with themetallic mounting rail of the mounting unit so that the first endcontacts exposed metal of the mounting rail to establish electricalbonding between the clamp and the mounting rail. The method additionallyincludes coupling the second end of the clamp with the solar panelpositioned atop the mounting unit so that the second end electricallycontacts the solar panel and thereby establishes electrical bondingbetween the mounting rail and the solar panel.

Wind Deflector Members

In some embodiments it may be desired to couple adjacent units with amember that spans a lateral gap between the units. The coupling membermay function to deflect wind for various purposes, such as to reducewind uplift forces. FIGS. 13A-13C illustrate various embodiments of acoupling member that may be used to span a lateral gap between adjacentmounting units and/or reduce wind uplift forces. As shown in FIG. 13A, acoupling unit 1308 is coupled with a first mounting unit 1302 and asecond mounting unit 1304 between a lateral gap 1306 between the units.The coupling member 1308 is a rectangular object that is positionable tospan the gap 1306 between the two units. The coupling member 1308 may bemade of various materials including, in a specific embodiment, the samematerial as the mounting units themselves. In other embodiments, thecoupling component 1308 may be made of metal, metal alloy, plastic,plastic composite, wood, or other suitably durable material. To couplethe coupling member 1308 with the two units, opposing edges of thecoupling member 1308 may be inserted within slots 1310 of the respectivemounting units, 1302 and 1304. The opposing edges of the coupling member1308 (e.g., snap flanged) may snap into engagement within the slots 1310of the adjacent mounting units. In other embodiments, the couplingcomponent 1308 may be secured to the rear wall of adjacent mountingunits by mechanical fastener(s), adhesive, tape, heat welding, and thelike.

When coupled with the mounting units, the coupling member 1308 may beangled with respect to the roof surface at roughly the same angle as arear vertical surface of the mounting units, 1302 and 1304. The angledorientation of the coupling member 1308 may aid in deflecting wind upand around the attached PV module. To further deflect wind up and aroundthe attached PV module, the coupling member 1308 may include an arcuateend portion 1312 that is positioned adjacent or slightly above a topsurface of the PV module as shown in FIG. 13C. The arcuate end portion1312 may minimize the wind that is able to access the undersurface ofthe PV module by directing wind over the top surface of the PV module,which may reduce wind uplift forces. The attached coupling component1308 may further aid in reducing or preventing the accumulation ofdebris between the adjacent mounting units, 1302 and 1304, and/or underthe attached PV module. As shown in FIG. 13C, the coupling component1308 is normally attached to the rear surface of the adjacent mountingunits. In some embodiments, the coupling component may include geometricfeatures (not shown) such as ribs, channels, and the like, to increasethe flexural stiffness of the component 1308. I

In some embodiments, a bottom edge of the coupling component 1308 may bepositioned so as to be raised above the roof structure by between 0.125inches and 6 inches, and more commonly about 2 inches. The top of thecoupling component 1308 may be positioned to be below the bottom of thesolar panel by between 0 and 6 inches, except in instances where the topof the coupling component 1308 is positioned to extend above the top ofthe PV module as shown in FIG. 13C.

Having described several embodiments, it will be recognized by those ofskill in the art that various modifications, alternative constructions,and equivalents may be used without departing from the spirit of theinvention. Additionally, a number of well-known processes and elementshave not been described in order to avoid unnecessarily obscuring thepresent invention. Accordingly, the above description should not betaken as limiting the scope of the invention.

Where a range of values is provided, it is understood that eachintervening value, to the tenth of the unit of the lower limit unlessthe context clearly dictates otherwise, between the upper and lowerlimits of that range is also specifically disclosed. Each smaller rangebetween any stated value or intervening value in a stated range and anyother stated or intervening value in that stated range is encompassed.The upper and lower limits of these smaller ranges may independently beincluded or excluded in the range, and each range where either, neitheror both limits are included in the smaller ranges is also encompassedwithin the invention, subject to any specifically excluded limit in thestated range. Where the stated range includes one or both of the limits,ranges excluding either or both of those included limits are alsoincluded.

As used herein and in the appended claims, the singular forms “a”, “an”,and “the” include plural referents unless the context clearly dictatesotherwise. Thus, for example, reference to “a process” includes aplurality of such processes and reference to “the device” includesreference to one or more devices and equivalents thereof known to thoseskilled in the art, and so forth.

Also, the words “comprise,” “comprising,” “include,” “including,” and“includes” when used in this specification and in the following claimsare intended to specify the presence of stated features, integers,components, or steps, but they do not preclude the presence or additionof one or more other features, integers, components, steps, acts, orgroups.

1. A mounting unit for mounting a solar panel on a roof comprising: abase that is configured for positioning adjacent the roof, the baseincluding a first flange and a second flange that extend laterally fromthe base; a mounting surface positioned above the base via walls thatconnect the mounting surface and the base, the mounting surface beingcouplable with the solar panel to elevate the solar panel above asurface of the roof and to orient the solar panel at an angle relativeto the roof; a flexible membrane material coupled with the first flangeof the base and extending laterally therefrom; and an adhesive or tapeapplied to an underside of the second flange, the second flange beingfree of the flexible membrane material; wherein the flexible membranematerial is couplable with the roof and the adhesive or tape isadherable to the roof to secure the mounting unit to the roof.
 2. Themounting unit of claim 1, wherein the base includes a third flange and afourth flange that extend laterally from the base, the first flange,second flange, third flange, and fourth flange extending around aperiphery of the base, and wherein the flexible membrane material iscoupled with only the first flange while the adhesive or tape is appliedto an underside of the second, third, and fourth flanges.
 3. Themounting unit of claim 2, wherein the first flange extends from a rearside of the base.
 4. The mounting unit of claim 2, wherein at least oneportion or segment of the adhesive or tape is separated by a gap.
 5. Themounting unit of claim 4, wherein the adhesive or tape is separated bytwo gaps that are positioned near opposing sides of the base.
 6. Themounting unit of claim 1, wherein the flexible membrane material is heatwelded to the roof, and wherein the adhesive or tape includes aremovable film that prevents or limits degradation of an adhesivematerial prior to adhering the adhesive or tape with the roof.
 7. Amethod of attaching a solar panel mounting unit to a roof comprising:providing a solar panel mounting unit having: a base that includes afirst flange and a second flange that extend laterally from the base; amounting surface positioned above the base via walls that connect themounting surface and the base, the mounting surface being couplable witha solar panel to elevate the solar panel above a surface of the roof andangle the solar panel relative thereto; a flexible membrane coupled withthe first flange of the base and extending laterally therefrom; and anadhesive or tape applied to an underside of the second flange, thesecond flange being free of the flexible membrane material; coupling theflexible membrane material with the roof to secure the solar panelmounting unit to the roof; and adhesively bonding the adhesive or tapewith the roof to additionally secure the mounting unit to the roof. 8.The method of claim 7, further comprising: coupling the flexiblemembrane material with only the first flange of the base; and applyingthe adhesive or tape with an underside of at least one other flange ofthe base other than the second flange.
 9. The method of claim 8, whereinthe first flange is positioned near a rear side of the base.
 10. Themethod of claim 8, further comprising forming a gap in at least oneportion or segment of the adhesive or tape.
 11. The method of claim 10,wherein the second flange is positioned near a front side of the baseand wherein the adhesive or tape is applied to a third and fourth flangethat are positioned on opposing sides of the base between the front sideand a rear side, and wherein the method further comprises forming twogaps in the adhesive or tape near the third and fourth flanges.
 12. Themethod of claim 8, wherein the base includes a third flange and a fourthflange that are positioned between the first flange and the secondflange, and wherein the method further comprises: attaching the flexiblemembrane material to only the first flange; and applying the adhesive ortape to an underside of the second flange, the third flange, and thefourth flange such that the second flange, third flange, and fourthflange are free of the flexible membrane material.
 13. The method ofclaim 7, further comprising: heat welding the flexible membrane materialto the roof; and removing a film from the adhesive or tape prior toadhesively bonding the adhesive or tape with the roof, the filmpreventing or limiting degradation of an adhesive material.
 14. Themethod of claim 7, wherein coupling the flexible membrane material withthe roof comprises bonding the flexible membrane material to the roofwith an adhesive or tape, and wherein the method further comprisesremoving a film from the adhesive or tape prior to bonding the adhesiveor tape with the roof, the film preventing or limiting degradation ofthe adhesive material.
 15. The method of claim 7, further comprisingaligning a plurality of mounting units atop a roof by: coupling aflexible membrane material of a first mounting unit with the roof;positioning a front flange of a second mounting unit atop the flexiblemembrane of the first mounting unit; and adhesively bonding, via theadhesive or tape, the front flange of the second mounting unit with theflexible membrane of the first mounting unit.
 16. The method of claim 7,further comprising laterally spacing a plurality of mounting units atopthe roof by: providing a spacing jig comprising: a first longitudinalsection; a first flange member that extends from a proximal end of thefirst longitudinal section; a second longitudinal section telescopinglydisposed within the first longitudinal section; and a second flangemember that extends from a distal end of the second longitudinalsection; positioning a first mounting unit atop the roof; positioning asecond mounting unit atop the roof; positioning the first flange memberof the spacing jig within a slot of the mounting surface of the firstmounting unit; and positioning the second flange member of the spacingjig within a slot of the mounting surface of the second mounting unit,wherein said positioning of said first and second flange members withinsaid respective slots spaces said first and second mounting units. 17.The method of claim 7, further comprising longitudinally spacing aplurality of mounting units atop the roof by: providing a spacing jigcomprising: a first longitudinal section; a first flange member that ispivotally attached to a proximal end of the first longitudinal section;a second longitudinal section coupled with the first longitudinalsection so as to have an angled orientation relative thereto; and asecond flange member that extends from a distal end of the secondlongitudinal section; positioning a first mounting unit atop the roof;positioning a second mounting unit atop the roof; positioning the firstflange member of the spacing jig within a slot of the mounting surfaceof the first mounting unit; and positioning the second flange member ofthe spacing jig within a slot of the mounting surface of the secondmounting unit, wherein said positioning of said first and second flangemembers within said respective slots spaces said first and secondmounting units.
 18. A mounting unit for mounting a solar panel on a roofcomprising: a base; a plurality of walls that extend upward from thebase; and a mounting surface connected with and positioned above thebase via the plurality of walls; wherein the mounting surface includes aplurality of slots that are each configured to receive a couplingcomponent that facilitates in coupling the solar panel atop the mountingsurface, wherein each slot of the plurality of slots is reinforced bycoupling a mesh material with each slot of the plurality of slots,wherein each slot is reinforced to secure the solar panel atop themounting unit and thereby increase the wind uplift resistance of themounting unit, and wherein the mesh material is only coupled with eachslot so that a majority of the mounting unit is free of the meshmaterial.
 19. The mounting unit of claim 18, wherein the mesh materialis disposed within the mounting surface at each slot location.
 20. Themounting unit of claim 19, wherein the mesh material is vacuum molded orinsert molded into the mounting surface at each slot location.
 21. Themounting unit of claim 18, wherein the mesh material comprises a tapethat is attached to a top surface of the mounting surface at each slotlocation.
 22. The mounting unit of claim 21, wherein the mesh materialor tape is adhesively bonded with the mounting surface's top surface ateach slot location. 23.-41. (canceled)